US9458302B1 - Extrudable vehicular floor mat using recycled content - Google Patents
Extrudable vehicular floor mat using recycled content Download PDFInfo
- Publication number
- US9458302B1 US9458302B1 US14/825,931 US201514825931A US9458302B1 US 9458302 B1 US9458302 B1 US 9458302B1 US 201514825931 A US201514825931 A US 201514825931A US 9458302 B1 US9458302 B1 US 9458302B1
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- United States
- Prior art keywords
- foam
- laminate
- skin
- recycled
- crosslinked
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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- 239000006260 foam Substances 0.000 claims abstract description 56
- 229920000098 polyolefin Polymers 0.000 claims abstract description 20
- 229920002397 thermoplastic olefin Polymers 0.000 claims abstract description 18
- 239000000203 mixture Substances 0.000 claims description 51
- 229920006124 polyolefin elastomer Polymers 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 20
- 239000000945 filler Substances 0.000 claims description 17
- 239000000314 lubricant Substances 0.000 claims description 17
- 239000000463 material Substances 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 16
- 239000002184 metal Substances 0.000 claims description 16
- 150000003839 salts Chemical class 0.000 claims description 16
- -1 polyethylene Polymers 0.000 claims description 13
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 12
- 229910017053 inorganic salt Inorganic materials 0.000 claims description 12
- 150000001732 carboxylic acid derivatives Chemical class 0.000 claims description 9
- 238000010128 melt processing Methods 0.000 claims description 9
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 7
- 229920001155 polypropylene Polymers 0.000 claims description 7
- 239000011496 polyurethane foam Substances 0.000 claims description 7
- 239000001993 wax Substances 0.000 claims description 7
- 239000004743 Polypropylene Substances 0.000 claims description 6
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 6
- 239000000155 melt Substances 0.000 claims description 6
- 239000012188 paraffin wax Substances 0.000 claims description 6
- 239000004698 Polyethylene Substances 0.000 claims description 5
- 229920000573 polyethylene Polymers 0.000 claims description 5
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 3
- 229910000021 magnesium carbonate Inorganic materials 0.000 claims description 3
- 239000001095 magnesium carbonate Substances 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims 1
- 239000004814 polyurethane Substances 0.000 claims 1
- 238000004064 recycling Methods 0.000 abstract description 20
- 229920005989 resin Polymers 0.000 abstract description 7
- 239000011347 resin Substances 0.000 abstract description 7
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 238000009472 formulation Methods 0.000 description 16
- 239000004615 ingredient Substances 0.000 description 11
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 9
- 230000015572 biosynthetic process Effects 0.000 description 5
- 239000005038 ethylene vinyl acetate Substances 0.000 description 5
- 229930195733 hydrocarbon Natural products 0.000 description 5
- 150000002430 hydrocarbons Chemical class 0.000 description 5
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 239000004215 Carbon black (E152) Substances 0.000 description 3
- 239000006057 Non-nutritive feed additive Substances 0.000 description 3
- 125000001931 aliphatic group Chemical group 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 3
- 239000000806 elastomer Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 239000002648 laminated material Substances 0.000 description 3
- 239000002952 polymeric resin Substances 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 150000001336 alkenes Chemical class 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920005672 polyolefin resin Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 101100042016 Caenorhabditis elegans npp-20 gene Proteins 0.000 description 1
- 102100026816 DNA-dependent metalloprotease SPRTN Human genes 0.000 description 1
- 101710175461 DNA-dependent metalloprotease SPRTN Proteins 0.000 description 1
- 229920002943 EPDM rubber Polymers 0.000 description 1
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 229920003020 cross-linked polyethylene Polymers 0.000 description 1
- 239000004703 cross-linked polyethylene Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920013716 polyethylene resin Polymers 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 229920001935 styrene-ethylene-butadiene-styrene Polymers 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J11/00—Recovery or working-up of waste materials
- C08J11/04—Recovery or working-up of waste materials of polymers
- C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2300/00—Characterised by the use of unspecified polymers
- C08J2300/16—Biodegradable polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2475/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2475/04—Polyurethanes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Definitions
- the present invention relates generally to the manufacture of vehicular floor mats using recycled content.
- the present disclosure identifies the ability to form extrudable floor mats suitable for interior vehicular applications where the recycle content includes recycling of selected mounts of a laminate of crosslinked polyolefin foam and thermoplastic polyolefin resin.
- Vehicular floor mats are a common accessory for many vehicles, as part of an effort to protect carpeting and other interior components. As vehicular floor mats derive from various polymer resin compositions, it would be useful to identify particular polymer resin compositions, from recycling channels, that may be suitable to otherwise satisfy the performance requirements of floor mats that are often used in various demanding environments.
- vehicular floor mats must be, e.g., sufficiently strong to withstand the abuse of different types of shoes and different abrasive action when entering or leaving a vehicle as well as when the driver is operating the vehicle.
- vehicular mats must endure various chemicals and debris.
- vehicular mats are such that they desirably absorb or otherwise manage noise while providing an attractive surface appearance.
- vehicular floor mat compositions that may be sourced from recycled resins and otherwise provide an environmentally more friendly vehicular floor mat that may also satisfy one or more of the property requirements noted above.
- a method for forming a recycled composition for a vehicular mat comprising:
- a method for forming a recycled composition comprising:
- a recycled composition comprising:
- the present disclosure relates to the manufacture of a vehicular floor mat using recycled content. More specifically, the vehicular floor mats produced herein preferably utilizes recycled content that amounts to recycling of a previously formed skin-foam laminate material. More specifically, the skin-foam bilaminate material suitable for recycling herein is one that comprises a thermoplastic olefin skin that is laminated to a cross-linked polyolefin foam layer. Such skin-foam laminates may be sourced from what is often time identified as automotive hard trim scrap, from the manufacture of, e.g., instrument panels and door components.
- thermoplastic polyolefin is reference to those polymer resins that include some amount of olefin resin such as polypropylene and/or polyethylene.
- Such resins therefore may include blends of an olefin resin and an elastomer (e.g. ethylene-propylene rubber, ethylene-propylene diene rubber, styrene-ethylene-butadiene styrene rubber) in which the olefins are the major continuous phase and the elastomer is a relatively minor dispersed phase.
- elastomer e.g. ethylene-propylene rubber, ethylene-propylene diene rubber, styrene-ethylene-butadiene styrene rubber
- These blends may be preferably created either by melt blending or by reactor manufacture.
- TPO's exhibit both thermoplastic (capable of melt processing) and elastomeric properties, i.e., the materials process as thermoplastics but have some physical properties possessed by elastomers such as relatively high elongations of over 50%. More preferably, the elongations will fall in the range of 100% to 250%.
- the thermoplastic polyolefins herein will also preferably have a density in the range of 0.85 g/cc to 1.1 g/cc.
- crosslinked polyolefin foam layer which may therefore include crosslinked polyethylene or crosslinked polypropylene.
- crosslinked is reference to the feature that a portion of the polymer chains are covalently crosslinked, which may be achieved by irradiation or chemical treatment. Such crosslinking will typically improve mechanical properties and thermal stability.
- crosslinked polyolefin foam that is preferably recycled herein includes crosslinked polyolefin foam that is available from Sekisui-Voltek, under the trade names VOLARATM, which foam may have a density from 2 pcf to 20 pcf and a thickness of 0.010′′ to 2.00′′, more preferably 0.075′′ to 0.165′′.
- Such foams also indicate a tensile strength in the machine direction that falls in the range of 60 psi to 200 psi, depending upon density.
- the foams also have a compression set (ASTM D 2240) in the range of 8% of original thickness to 25% of original thickness.
- the skin-foam laminates that are recycled herein are preferably those where the weight percent of thermoplastic polyolefin is about 10.0% wt. to 35.0% wt. and the corresponding weight percent of crosslinked polyolefin foam is 90.0% wt. to 65.0% wt.
- the skin-foam laminate itself is preferably present in the recycled mixture at a level of 40.0% wt. to 60.0% wt.
- the skin-foam bilaminate herein may be preferably and initially melt processed and formed into pellets for further recycling herein and formation of a vehicular mat, or used directly in any of the recycled mat formulations described herein.
- the recycling of the skin foam-laminate noted above has been found to be effectively improved by the addition of a polyolefin elastomer which is included to increase melt strength and/or impact characteristics of the final recycled resin.
- the polyolefin elastomer is a functionalized polyethylene resin such as an ethylene-maleic anhydride copolymer and may include up to 8% ethylene-vinyl acetate copolymer.
- Such polyolefin elastomer preferably has a density in the range of 0.85 g/cc to 0.92 g/cc, more preferably in the range of 0.85 g/cc to 0.90 g/cc, and in particular can have a density of 0.87 g/cc.
- the melt index is preferably in the range of 3 g/10 min to 7 g/10 min, more preferably, in the range of 4 g/10 min to 6 g/10 min.
- the tensile strength at break is preferably in the range of 800 psi to 1200 psi, more preferably 900 psi to 1100 psi.
- the elongation to break is preferably in the range of 1700% to 2100%, and more preferably, in the range of 1800% to 2000%.
- the Shore A hardness is preferably in the range of 50 to 70, more preferably 55 to 65.
- the resins preferably have a melting point in the range of 115° C. to 125° C.
- One particular preferred polyolefin elastomer includes a material sold by Spartan Polymer, Inc., under the name Enhance Recoil MMI.
- the level of such polyolefin elastomer that may be included in the recycling of the skin-foam laminate is such that it is present in the recycled mixture at a level of 10.0% wt. to 20.0% wt. More preferably, the level of the polyolefin elastomer may be in the range of 13.0% wt. to 17.0% wt., and in one particularly preferred embodiment, the level of polyolefin elastomer is present at a level of 15.0% wt.
- ingredients in the recycled formulation add-up to 100% wt. Accordingly, it can be appreciated that the particular ingredient selected below, and its corresponding amount, may vary.
- the first such ingredient that may optionally be used to improve the recycling of the skin-foam laminate herein is what is identified as a lubricant or processing oil.
- a lubricant or processing oil Such may be understood as an additive that improves the processing of the recycled mixture by improving the flow properties (e.g. reducing overall viscosity) and/or reducing the adherence of the recycled mixture to machine parts.
- Such lubricants may preferably be selected from hydrocarbons and in particular aliphatic based hydrocarbons that are liquid or waxes at room temperature. These may be selected from natural paraffin, synthetic paraffin, polyethylene waxes and/or polypropylene waxes. In general, such materials are those that have a MW of less than or equal to 2500 g/mole.
- One particularly preferred lubricant or processing oil that may be utilized herein includes an aliphatic/naphthenic oil, which is reference to a hydrocarbon type oil that specifically includes cycloparaffin type components. Such aliphatic/naphthenic oil is available from Eastern Oil Company and sold under the trade name PON1250.
- the lubricant or processing oil herein may therefore optionally be present in the recycling of the skin-foam laminate at a level of 0.1 wt. % to 5.0 wt. %, more preferably in the range of 1.0 wt. % to 3.0 wt. %, and in a particularly preferred embodiment, the lubricant or oil is present at a level of 2.5 wt. %.
- the next ingredient that is optionally included to improve recycling of the skin-foam laminate herein is what is identified as another processing aid, sourced from metal salts of carboxylic acids.
- such may include metal salts such as zinc stearate and/or calcium stearate.
- metal salts may preferably be sourced from Struktol under the trade name SA1335, which is a zinc stearate composition.
- SA1335 is a zinc stearate composition.
- SA1335 is a zinc stearate composition.
- SA1335 is a zinc stearate composition.
- a hydrocarbon oil base such as a polyethylene/polyester base, such as a formulation containing 20% wt. zinc stearate and 80% wt. of the hydrocarbon oil base.
- Such metal salts may optionally be present in the recycling of the skin foam laminate at a level of 0.05 wt. % to 0.5 wt. %, more preferably, 0.05 wt. % to 0.20 wt. %, and most preferably, 0.1 wt. %.
- the remaining optional ingredient that one may utilize to improve the recycling of the skin-foam laminate herein is an inorganic salt filler, which may be included to modify one or more properties, such as increasing density, reduce shrinkage, increase hardness, increase heat distortion temperature, and cost reduction.
- Such may therefore include salts such as inorganic metal carbonates, such as calcium carbonate and/or magnesium carbonate.
- the inorganic metal salt fillers may optionally be present in the recycling of the skin-foam laminate herein at a level of 20.0% wt. to 40.0% wt., more preferably 25.0% wt. to 35.0% wt., and in a particularly preferred embodiment, the inorganic metal salt filler is present at a level of 30.0 wt. % to 35.0 wt. %.
- the skin-foam laminate herein is preferably recycled herein by melt processing, such as by extrusion, in preferably on a twin-screw type extruder.
- the extruder is preferably fed at a rate of about 5 kg/hr to 15 kg/hr, more preferably at a rate of about 8 kg/hr to 12 kg/hr, and in a most preferred embodiment, at a rate of 10 kg/hr.
- Barrel pressure is preferably set in the range of 600 psi to 800 psi, more preferably in the range of 650 psi to 750 psi.
- the extruder is preferably a multi-zone extruder where one may employ a temperature profile of selected temperatures in the range of 100° C. to 200° C.
- the extruder is a multi-zone twin-screw extruder which as the following zone heating profile set temperatures, extending from the feed throat region to the extruder nozzle: Zone 1: 190° C., Zone 2: 193° C.; Zone 3: 193° C.; Zone 4: 190° C.; Zone 5: 190° C.; Zone 6: 190° C.; Zone 7: 121° C.; Zone 8: 121° C.; Zone 9: 149° C.; Zone 10: 171° C. It is noted that the reduction in the temperatures set for Zones 7 through Zone 9 is due to the feature that there is then sufficient shearing and corresponding heating to allow for reduced set temperatures at such location of the extruder barrel.
- melt processing of the skin-foam laminate herein is therefore such that it will allow for melt processing and formation of recycled material suitable for use as a vehicular mat, in a desired dimension and thickness for a given mat application.
- the melt processing of the preformed skin-laminate herein by extrusion and/or injection molding will provide a molded composition.
- the recycled material may itself preferably be molded by extrusion processing to have a length in the range of 1.5 ft to 6.0 ft and a width in the range of 2.0 ft. to 6.0 ft and at a thickness in the range of 1.0 mm to 4.0 mm.
- an exemplary recycled formulations were prepared that included the following ingredients described herein:
- FOG:GMW3235 is reference to a General Motors Worldwide testing determination of the relative fogging tendency of an interior automotive component
- GMW147 is a corresponding testing protocol of the indicated tensile and elongational properties
- TO is reference to Tinnius Olsen stiffness testing.
- recycling of the skin-foam laminate herein provides a material that is suitable for a vehicular mat and one that that will have a tensile strength of at least about 4.0 MPa (ISO37).
- the tensile strength of the material utilized for formation of the recycled mat herein is contemplated to fall in the range of 4.0 MPa to 8.0 MPa.
- the elongation of the material utilized for formation of the recycled mat herein is one that will have a minimum elongation of 500%, and one that is contemplated to fall in the range of 500% to 700%.
- the tear strength of the recycled mat is also seen to have a minimum value of about 150 N and is contemplated to fall in the range of 150 N to 180 N.
- the melt flow rate of the recycled material composition herein has a value of greater than 80 g/10 min, more preferably in the range of 80 g/10 min to 125 g/10 min.
- the above identified formulation for forming of a recycled mat comprising 40.0% wt. to 60.0% wt. of a preformed skin-foam laminate wherein the skin comprises a thermoplastic olefin and the foam comprises a crosslinked polyolefin, 10.0% wt. to 20.0% wt. of a polyolefin elastomer, and one or more of 0.1 wt.
- % to 5.0 wt. % of a lubricant may also include 5-15% wt. of a crosslinked polyurethane foam.
- Such ingredients then may be melt processed and formed into a recycled molded composition.
- This formulation when extruded and formed into mat, indicates a FOG GMW of 1.06, Tensile ASTM D5034 of 314 N, Tensile and Elongation GMW147/ISO 37 of 14.0 MPa and 601%, Tear Strength (N) New Moo76, Sec. 13 of 139N, Tinnius Olsen stiffness of 51.68, Tensile Strength at Break ASTM D412 of 4605 MPa, Tensile Elongation at Break ASTM D412 of 442%.
- another recycled formulation that contains: (1) 25 wt. % to 45 wt. % of the previously formed skin-foam laminate material, which as noted, is preferably composed of a thermoplastic olefin skin laminated to cross-linked polyolefin foam; (2) 40 wt. % to 60 wt. % of a regrind whose preferred composition is noted below and contains crosslinked polyurethane foam; (3) 0.1 wt. % to 0.5 wt. % of antioxidant; (4) 0.1 to 5.0 wt. % of a lubricant or processing oil; (5) 10 wt. % to 20 wt. % of an ethylene-vinyl acetate copolymer, more preferably 10 wt. % to 15. wt. % of such copolymer, which serves to improve the compatibility of this recycled mixture.
- the preferred regrind noted above is one that as noted includes and provides crosslinked polyurethane foam, and such regrind is also preferably one that may have been previously applied as a layer of a vehicular firewall, which may now be recycled as noted above.
- One particular layer of such firewall material that can be used for recycling itself contained 85-95% by weight of a blend of EVA, olefins, and fillers and 5.0 to 15.0% by weight of recycled crosslinked polyurethane foam.
- the EVA preferably has a melt index of 5 to 15 with a vinyl acetate content of 10 to 30, a 4 to 10% by weight blend of fractional to 10 melt index poly(propylene) or ethylene/propylene copolymers, 1-3% wt. of linear low density poly(ethylene) with a melt index of 80 to 200, 75-80% of the total blend weight comprised of a filler or filler blend consisting of calcium carbonate or barium sulfate, or a blend thereof.
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- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
Abstract
Description
-
- 0.1 wt. % to 5.0 wt. % of a lubricant;
- 0.05 wt. % to 0.5 wt. % of a metal salt of a carboxylic acid;
- 20.0 wt. % to 40.0 wt. % of an inorganic salt filler;
TABLE 1 |
Recycled Mat Formulation |
Component | Wt. % |
Skin Foam Laminate (thermoplastic olefin skin | 50 |
laminated to crosslinked polypropylene) | |
Polyolefin Elastomer (Enhance Recoil MMI) | 15 |
Processing Aid ( PON 1250B) | 2.5 |
SA 1355 (20% zinc stearate/80% ester | 0.5 (providing 0.1 |
processing aide) | wt. % zinc stearate) |
Calcium Carbonate | 32 |
TABLE 2 |
Virgin Mat Formulation |
Component | Wt. % |
Engage DA 22 (polyolefin elastomer) | 27.5 |
Engage DA 53 I | 5.0 |
SA 1355 (20% zinc stearate/80% ester | 0.7 (providing 0.14 |
processing oil) | wt. % zinc stearate) |
Ateva 2810 (ethylene-vinyl acetate copolymer) | 27.5 |
Processing Aid PON 1250B | 4 |
Carbon Black | 0.3 |
Calcium Carbonate | 35 |
TABLE 3 |
Property Comparison |
Recycled Mat v. Virgin Formulation |
Tear | Tensile | |||||||
Tensile & | Strength(N) | MFR | Strength | Tensile | ||||
Tensile | Elongation | NEW | 190° C. | TO | at Break | Elongation at | ||
ASTM | GMW147/ | Moo 76 | 21.6 | Stiffness | ASTM | Break | ||
Sample | FOG:GMW3235 | D5034 | ISO 37 | Sec 13 | KG | Test | D412 | ASTM D412 |
Recycled | 1.04 | 586N | 4.64 MPa | 158.5N | 93.42 g/ | 33.73 | N/A | N/A |
Mat (Table | (Tensile) | 10 min | ||||||
1) | 566% | |||||||
(Elongation) | ||||||||
Virgin | 0.77 | 693N | 14.0 MPa | 190N | 221.29 g/ | 52.37 | 10,539 | 816.4% |
Formulation | (Tensile) | 10 min | MPa | |||||
(Table 2) | 601% | |||||||
(Elongation) | ||||||||
Claims (21)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/825,931 US9458302B1 (en) | 2015-08-13 | 2015-08-13 | Extrudable vehicular floor mat using recycled content |
Applications Claiming Priority (1)
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US14/825,931 US9458302B1 (en) | 2015-08-13 | 2015-08-13 | Extrudable vehicular floor mat using recycled content |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US20220048225A1 (en) * | 2020-08-13 | 2022-02-17 | Puren Gmbh | Continuous method for producing a functional material, a raw mass for a functional material, and a functional material |
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US5725926A (en) | 1997-01-16 | 1998-03-10 | Wang; Ming-Ling | Car floor mat |
WO2001074206A2 (en) | 2000-04-05 | 2001-10-11 | Walk Off Mats Limited | Mat, method of manufacturing a mat and method of recycling mats |
US20040048035A1 (en) | 2002-09-06 | 2004-03-11 | Racemark International, Inc. | Recyclable floor mats, methods and systems for recycling floor mats |
US20110039051A1 (en) | 2009-08-14 | 2011-02-17 | Flowers Jr Willis E | Floor mat |
US8329810B2 (en) | 2010-01-07 | 2012-12-11 | Lion Copolymer, Llc | Elastomeric compounds containing recycled materials and silica |
-
2015
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Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5725926A (en) | 1997-01-16 | 1998-03-10 | Wang; Ming-Ling | Car floor mat |
WO2001074206A2 (en) | 2000-04-05 | 2001-10-11 | Walk Off Mats Limited | Mat, method of manufacturing a mat and method of recycling mats |
US20040048035A1 (en) | 2002-09-06 | 2004-03-11 | Racemark International, Inc. | Recyclable floor mats, methods and systems for recycling floor mats |
US20110039051A1 (en) | 2009-08-14 | 2011-02-17 | Flowers Jr Willis E | Floor mat |
US8329810B2 (en) | 2010-01-07 | 2012-12-11 | Lion Copolymer, Llc | Elastomeric compounds containing recycled materials and silica |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US20220048225A1 (en) * | 2020-08-13 | 2022-02-17 | Puren Gmbh | Continuous method for producing a functional material, a raw mass for a functional material, and a functional material |
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